Method for forming tire molds



May 5, 1942.

J.'W. BISHOP ETAL METHop FoR"FoRMINQ TIRE MoLDs K Filed Augv. 31, 1937 2- Sheets-Sheet l INVENToRs JOSEPH w. BISHOP ARTHUR w. BULL ,May 5 1942- 1w. BlsHoP Erm. 2,282,022

METHOD FOR FpRMING TIRE MLDs Filed Aug. 31, 1957' 2 Sheets-Sheet 2 v iNl/NoRs JOSEPH w BffsHoP ARTHUR Af-'BULL f 'BY ATTORNEYS..

tro-deposition.

Patented May 5, 1,942

2,282,022 K METHOD FOR FOERUNG TIRE MOLDS Joseph W. Bishop, Detroit, and Arthur W. Bull,

Grosse Pointe, Mich., assirnors, by meme assignments, to United States Rubber Company, New York, N. Y., a corporation of New Jersey Application August 31, 1937, Serial No. 161,736

4 Claims.`

l This invention relates to molds, and in particular to molds for pneumatic tires. More particularly, the invention relates to the formation Vof tire molds by the electrolytic deposition of a ferrous metal. In general, the invention comprises the formation of molds the contour of which is determined by a matrix over which a metallic shell is formed `primarily by electro-deposition, while deficiencies due to irregularities in plating are corrected by atomized thermal deposition of metal.

While the idea of forming molds by electrolytically depositing a shell pf metal over non-metallic and electrically non-conductive surfaces is not new, use of this process as adapted to the construction of molds employed particularly in the manufacture of rubber tires has not been considered commercially satisfactory. Prior processes have been objectionable due to the diiculty of commercially electro-depositing a ferrous metal; one disadvantage among others being the difliculty of maintaining uniformity of thickness of electro-deposited metal, since in the process of electrolytically depositing a ferrous shell over a cathode of intricate design metal sometimes forms in thick deposits on areas near an anode while other areas and obscure corners receive little or no deposit of metal. The high cost of manufacture has also presented a'problem difcult to overcome. y

The process of the present inventionv permits the production of a satisfactory tire mold by using a rubber form as a matrix on which an appropriate metal such as iron is deposited. Thus, in manufacturing a plurality of similar molds the difficulty of manually engraving a design for each individual mold is obviated, resulting in a considerable saving in cost of manufacture over the conventional mode of constructing tire molds. Furthermore, molds produced by our method are capable of withstanding constant daily use over as long a period as that obtained by molds of standard construction.

Another advantage of the mold constructed in :accordance with our process is that, due to its multiple construction, parts of the mold which become defective or obsolete may be replaced without the necessity of discarding the mold in its entirety.

An additional advantage is thel ease with which objectionable deficiencies in the 4electro-deposited ferrous metal may be corrected by application of thermo-atomized metal without interfering with advantages accompanying' continuous elecvtwo modes of applying metallic deposits to` a matrix permits the formation of a homogeneous shell of ferrous metal. i

Still another advantage derived in the use of the present process is the uniformity in thickness of the ferrous deposit on the matrix resulting from the'dual deposition method, in combination with Acoinliaratively low cost.

These and other objects and advantages will appear more fully in the following detailed description when considered in connection with the accompanying drawings, in which:

Fig. 1 is a Vertical view, in section, of a transaxial portion of a pneumatic tire mold;

Fig. 2 is a similar view showing a rubber matrix formed therein;

Fig. 3 is a fragmentary view, in section, illustrating a completed matrix;

Fig. 4 is a Vertical view, in section, illustrating a plating tank and cathode rotating mechanism associated therewith;

Fig. 5 is a vertical view, in section, taken on section line V-V of Fig. 4; with the cathode and attached mechanism in raised position;

Fig. 6 is a trans-axial view lof a matrix after a deposit of metal has been applied thereto;

Fig. 7 is a trans-axial view, in section, of a shell opposing, substantially parallel, surface 3 adapted l to contact and register with a corresponding side of a second trans-axial portion of a mold to form a complete tire mold. A circular cavity 4 formed in the mold at the surface 3 includes a pattern or design 5 which may be in the form of any desired tread configuration used in pneumatic tires.

In order to produce a satisfactory matrix on which ferrous metal can be deposited, with the accompanying minimum of shrinkage and deformation of said matrix, it is preferable to employ a back plate 6 (Fig. 2) having an annular convex portion 1 integral therewith to support `the contour of the matrix. When the parts are positioned in relationship with each other, as shown in Fig. 2, the convex side of the back plate projects into the mold cavity 4 and affords a substantially uniform space between walls thereof Also,V the coordination of the and the adjacent surface of the mold cavity. Itis v effective bonding of rubber to metal, such as by ilrst electro-plating the convex side with brass.

A matrix is formed by vulcanizing rubberA in bonded relation with the convex side of the back plate 6, the exterior of the matrix assumingthe configuration of the mold cavity. To eifect this operation, uncured compounded rubber is cemented to the convex side of the back plate 6 or is placed'in the mold cavity, the backplate and mold I are brought together under pressure, and the rubber issubjected to vulcanization. Upon disengagement oi' the plate from the mold, a matrix 8 has been formed, with a contour adequately supported and assuming a trans-axial replica of a pneumatic tire.A The matrix is made in transaxial form because it is customary to form tire molds in two separate units which when assembled. form a. complete pneumatic tire mold split along thetrans-'axial plane. l

An electrical insulation covering 9 of any suitable material `such-as rubber is applied to the exposed'- metal surface of the-back plate 6, care being taken to leave areas I and II adjacent the rubber matrix exposed, as shown in Fig. 3, to afford an electrically conductive surface to the matrix. In order to render the `non-conductive matrix surface electrically conductive, the surface thereof is painted or treated with a suitable material such as powdered carbon or graphite.

The thus assembled matrix 8 and back plate 6 are secured to a spider I2 in any convenient manner, preferably byV bolts I3, I3,v as shown in Fig. 5. The spider, in turn, is secured to a spindle I4 having sheaves I5 and I6 mounted at each end. 'I'he sheaves I5 and I6 engage with belts I1 `and I8, respectively, and by means of the belts the weight of the spindle and attached parts is supported in a solution I9 contained in a rubber lined tank 20. One end of the shaft I4 engages with a connecting link 2I, by means of a stud screw 22, in a manner permitting attachment of the link to the spindle, but allowing rotation of the stud 22 within the link 2|. Mounted at one side of the tank 20 and electrically insulated therefrom is an electrical terminal 23 (Fig. 4) which is connected to the link 2| by an arm 24. A swivel joint at each end of the arm 24 allows substantially vertical movement of the matrix, yet assures effective electrical conductivity between a lead wire 25 and the surface of the matrix 8.

In order that current conducting parts such as the link 2l, screw 22, pulleys I5 and |61, spindle I4, and spider I2 will afford no bare surfaces to tion. Proper acidity of the solution may be effected by the addition of suitable quantities of hydrochloric acid. In operation the matrix functions as a cathode upon which metallic iron from "the'solution is deposited. The plate 26 acts as the anode and dissolves in the solution, compensating for the loss of salts originally contained therein.

In` order to' avoid brittleness'of the electroformed-metal shell, it is preferable to heat the solution. This is accomplished by providing a heating coll 3| which may be connected to a source for generating steam. It has been found desirable .to maintain the solution at a temperature between 175 Fahrenheit and 195 Fahrenheit.

During the electroforming process a more unil electrolytic metal than have surrounding areas,

and this property is further accentuated as a deposit thus formed grows toward the anode.

Rotation of the cathode is effected by a mechanism 32 mounted on a platform 33 supported by upright posts 34 and 35 and obliquely disposed braces 36 and 31. The lower extremities of the posts and braces are secured to the tank 20 while the upper ends are joined together at a pivot shaft 38 to which the platform 33 is pivotalp 1y connected. The platform is free to swing upattract a deposit of ferrous metal when immersed Adjacent one side of the tank 20 and opposite the matrix 8 a plate of ferrous metal 26 (Figs. 4

and 5) is suspended from a bus bar 21 by means of hooks 28. The extremity of the bus bar passes beyond the exterior of the tank and has mounted,

at the end thereof, an electrical terminal 29 to f which a lead wire 3|) is connected.

Although a number of ferrous plating solutions are well known in the electro-deposition art, good results have been obtained from a solution composed of 100 grams of ferrous chloride and 200 grams of calcium chloride per liter of soluwardly but is limited in downward movement Y by a cross-rail member 39 afilxed to the braces 36 and 31. A foot member 40 attached to the base of the platform 33 is adapted to contact with the cross-rail 33. A motor 4I mounted von the platform 33 imparts rotative motion to the pulley 42 through a gear reduction unit 43,`pulley 44, and belt 45. The pulley 43 is keyed to a shaft 46 and drives pulleys 41 and 48 also rigidly secured to said shaft. The weight of the catho ie assembly is sustained by the'belts I1 and I8 passing over the pulleys 41 and 48, respectively. Bearings 49 and 50 mounted on the platform 33 support the shaft 46. By this disposition of driving means the cathode is rotated about its axis during deposition.

It ls well known in the electro-plating art that the more remote on the cathode receive less deposit v than generally exposed surfaces. For example, in electro-forming a. metallic shell about a matrix, as hereinbefore described, it has been found that electro-deposited metal does not accumulate readily in areas such as in the corner 5I (Fig. 3).

To correct this deficiency the cathode is raised to the extent that a portion thereof projects above the surface of the electrolyte. Fig. 5 illustrat s the cathode in its raised position. Any conv nient means, such as a rope 52 connected to a hook .53 secured to the bearing 53, may be utilized to elevate the cathode. Thermo-atomized metal is then sprayed into the corner 5I, while the cathode is rotated. Means for depositing the thermo-atomized metal is provided in the form of a conventional apparatus 54 capable of generating and depositing fine particles of a metal such as iron in desired areas of the metal shell. Thus, .electro-formed metal and thermoatomized metal are co-ordinated in such a way that the thin portions of the electro-formed shell are effectively built up esv by forming a illlet thereat. It has been found that` when a de- 4 ficiency is so corrected'the supplementary' metal and the electro-deposited metal form a homogeneous structure.

The current between the terminals Z3 and'ZQ having been maintained` vfor a sufficient period, a deposit of ferrous metal is formed on the latoniized thermo-deposition concurrently, and

cathode, preferably to an average depth of approximately 1A inch, to form a shell 55 (Fig. 6). After the deposition is completed the shell may be separatedfrom the matrix 8 and back plate 6 by heating the assembly in an oven to approximately 600 Fahrenheit, at'which temperature the rubber is readily pulled away from the shell. This heating also has an annealing eect which increases the tensile strength of the electroformed metal and renders it ymore suitable for machine operations. h l

The shell 55, having been segregated, as shown in Fig. '7, is provided with a metallic backing 56, for uniformly supporting the shell and for providing means for effectively securing the shell to an outer casing l of the nished mold. Effective rigid relationshipmay be established between the outer casing 5'! and the electro-formed shell 55 in any convenient manner; as, for example, the two may be appropriately positioned in a sand mold and melted metal -such as aluminum poured between them to occupy fully'the intervening space; or, a suitable back may be applied to the shell 55 by embedding the same in a sand mold, then pouring fused metalover the back thereof after which .the backing can be machined to a shape that will effectively registe with the interior of the casing.

As a modification of this practice, the shell 55 may be backed up with metal. applied by atomized thermal deposition. The sprayed metal thus deposited `may be machined to fit the contour of the outer casing 51.

In accordanceV with the method and apparatus herein described, its advantages with reference to practical commercial application are believed apparent, and it is intended to include those modiilcations of the invention Awhich appear within the scope of the appended claims.

Having thus described our invention, what we claim and desire to protect by Letters Patent is: 1. In a method of electro-forming pneumatic tire-molds, the steps 4confmrising forming and vulcanizing a curved relatively thin-walled ilex- -ible matrix of rubber composition in bonded recomprising causing relative movement betweenA a matrix, an active electrolytic bath and a source heating the matrix and the shell to break the bond therebetween, whereby said exible matrix may be readily withdrawn from said shell.

2. In a method of electro-forming pneumatic tire molds, the stepscomprising vulcanizing a curved matrix of flexible rubber composition in bonded relation with a rigid supporting plate, said matrix comprising an exposed face which conforms to the shape of at leastan elongated portion of a conventional tire and tread coniiguratiomtreating the exposed face of the matrix to provide an electrically conductive surface,

yforming at least a portion of a metallic shell about `the conductive face of the matrix by a concurrent electro-deposition and atomiz'ed thermo-deposition, and heating the matrix and shell to break the bond therebetween, whereby said exible matrix may be readily withdrawn from said shell., A

3. In a method of electro-forming pneumatic tire molds, the steps comprising vulcanizing'a matrix of flexible rubber composition in bonded relation with a rigid supporting plate, said matrix comprising an exposed face which conforms to the shape of at least an elongated portion of a conventional tire and tread configuration, treating the exposed face of the matrix to provide an electrically conductive surface, rotating the matrix in an electrolytic bath while formingl a metallic shell on the matrix by concurrent electro-deposition and atomized thermo-deposition, and heating the matrix and shell to break the bond therebetween, whereby said flexible matrix may be readily withdrawn from said shell.

4. In the method of making molds, the steps of thermally atomized metal, so as to bring portions of the matrix successively into positions to be treated by said bath and by said source, and simultaneously applying an electro-deposition o! metal and an atomized thermo-deposition of metal to portions oi the matrix whereby alternate layers of electrolytically and thermally deposited metals are concurrently formed upon the matrix.

JOSEPH W. BISHOP. lARTHUR W. BULL. 

